KX450 forks and clamps, 48mm, with custom adapter bushing, tapered roller bearings
i've previously used DRZ400S fully adjustable forks on my Versys bikes, 49mm conventional, 300mm travel, and very solid performers. simply massive in comparison to the OEM Versys 41mm USD forks.
Versys 41mm USD left, DRZ 49mm conventional right...
the DRZ400 forks are an easy swap to the Versys since the OEM Versys clamps are used along with inexpensive adapters. the swap recipe is well documented with both photos and narrative, mild to wild, very easy overall. add a 19" front wheel at the same time, then take your moto places you hadn't considered possible.
instead of DRZ forks, the 2019 Versys uses KX450 48mm USD forks, also fully adjustable, and 300mm travel. these forks are used with the KX450 clamps and are easy to fit. most clamps that fit forks sourced from the dirtbike world have a smaller center dimension so you want the pinch bolts facing the side or front to avoid interference. other 48mm forks could also be used, but forks from a Kawasaki seemed appropriate for the Versys. personally, i wouldn't fool with forks having stanchions less than 48mm, ain't worth the effort. worldwide, "Go big, or go home" will translate.
first, get rid of those stupid cheap OEM steering bearings, those price point things don't work well, have a short life, were probably never greased at the factory, and are not suited for use with the big suspension.
not hard to see the difference, roller bearing vs OEM ball bearing...
i use my handy shop-built bearing installation tool to install the races...
don't damage the receivers or races during the R&R process, and make sure that the new races are fully seated. note that the race sits slightly below the top edge of the receiver when seated, same on the bottom.
the KX450 stem does not match the Versys stem at the top in either length or diameter, but the 450 bearing race does work with the Versys roller bearing on the bottom, making the swap very straight forward. all that's needed is an adapter that mates the 450 stem OD to the Versys bearing ID, plus the height adjustment.
better get on the computer and create a CAD file so i can get the adapter machined, man, i'm fast with this techy nerd-o-matic stuff...
adapter on the steering bearing...
adapter with the KX450 top clamp...
the stem nut was fully engaged with the 10mm adapter flange, but i liked 7mm better and had it cut down to that dimension.
the steering stop on the Versys frame head stock was sized and positioned for the Versys clamps/forks and does not work with the KX clamps/forks setup, it needs fixin'.
i didn't want to add a piece of junk, wouldn't look right, better pick up the OD of the head stock, get out the white board, do some high level arithmetic...damn, this is hard work.
piece of scrap steel, 2.5" and 4" hole saws, single pilot hole, then make the cuts to 90%, snap it apart, smooth the edges, and you have a steering stop with perfect ID and OD radii.
position the new stop...
weld it in place...
now ya have an installed and functioning set of KX450 forks on the Versys frame.